Description
Hitachi ZX450-3, ZX450LC-3, ZX470H-3, ZX470LCH-3, ZX500LC-3, ZX520LCH-3 Excavator Operator’s Manual (EM1J1-1-1, ISM1J1-1-1)
ZX450-3, ZX450LC-3, ZX470H-3, ZX470LCH-3, ZX500LC-3, ZX520LCH-3 Excavator Index:
MACHINE NUMBERS
SAFETY
Recognize Safety Information …………………………………………… S-1
Understand Signal Words …………………………………………………… S-1
Follow Safety Instructions ………………………………………………….. S-2
Prepare for Emergencies …………………………………………………….. S-2
Wear Protective Clothing …………………………………………………… S-3
Protect Against Noise …………………………………………………………. S-3
Inspect Machine ………………………………………………………………….. S-3
General Precautions for Cab ………………………………………………. S-4
Use Handholds and Steps ………………………………………………….. S-5
Adjust the Operator’s Seat …………………………………………………. S-5
Ensure Safety Before Rising from or
Leaving Operator’s Seat ……………………………………………….. S-5
Fasten Your Seat Belt …………………………………………………………… S-6
Move and Operate Machine Safely …………………………………… S-6
Handle Starting Aids Safely ……………………………………………….. S-6
Operate Only from Operator’s Seat ………………………………….. S-7
Jump Starting ………………………………………………………………………. S-7
Keep Riders Off Machine ……………………………………………………. S-7
Precautions for Operations ………………………………………………… S-8
Investigate Job Site Beforehand ……………………………………….. S-9
Equipment of Head Guard, Rops, Fops ………………………….. S-10
Provide Signals for Jobs Involving
Multiple Numbers of Machines …………………………………. S-10
Confirm Direction of Machine to Be Driven …………………… S-10
Drive Machine Safely …………………………………………………………. S-11
Avoid Injury from Rollaway Accidents ……………………………. S-13
Avoid Injury from Back-over and Swing Accidents ………. S-14
Keep Person Clear from Working Area …………………………… S-15
Never Position Bucket Over Anyone ………………………………. S-15
Avoid Undercutting …………………………………………………………… S-15
Avoid Tipping ……………………………………………………………………… S-16
Never Undercut a High Bank ……………………………………………. S-16
Dig with Caution ………………………………………………………………… S-17
Operate with Caution ……………………………………………………….. S-17
Avoid Power Lines ……………………………………………………………… S-18
Precautions for Lightening ………………………………………………. S-18
Object Handling ………………………………………………………………… S-18
Protect Against Flying Debris ………………………………………….. S-19
Park Machine Safely …………………………………………………………… S-19
Handle Fluids Safely−avoid Fires …………………………………….. S-19
Transport Safely …………………………………………………………………. S-20
Practice Safe Maintenance ……………………………………………….. S-21
Warn Others of Service Work …………………………………………… S-22
Support Machine Properly ……………………………………………….. S-22
Stay Clear of Moving Parts ……………………………………………….. S-22
Prevent Parts from Flying …………………………………………………. S-23
Store Attachments Safely …………………………………………………. S-23
Prevent Burns ……………………………………………………………………… S-24
Replace Rubber Hoses Periodically …………………………………. S-24
Avoid High-pressure Fluids ………………………………………………. S-25
Prevent Fires ……………………………………………………………………….. S-26
Evacuating in Case of Fire …………………………………………………. S-27
Beware of Exhaust Fumes ………………………………………………… S-27
Precautions for Welding and Grinding …………………………… S-27
Avoid Heating Near Pressurized Fluid Lines ………………….. S-28
Avoid Applying Heat to Lines Containing
Flammable Fluids ………………………………………………………… S-28
Remove Paint Before Welding or Heating ……………………… S-28
Beware of Asbestos Dust ………………………………………………….. S-29
Prevent Battery Explosions ………………………………………………. S-29
Service Air Conditioning System Safely …………………………. S-29
Handle Chemical Products Safely ……………………………………. S-30
Dispose of Waste Properly ………………………………………………… S-30
SSAFETY SIGNS/Europe/Asia/Middle and
Near East Model Only ……………………………………………….. S-31
SAFETY SIGNS/North America and Oceania
Model Only ………………………………………………………………….. S-38
COMPONENTS NAME ……………………………………………………….. 1-1
OPERATOR’S STATION
Getting On / Off the Machine ……………………………………………. 1-2
Cab Features …………………………………………………………………………. 1-3
Multi Function Monitor ………………………………………………………. 1-5
Outline …………………………………………………………………………………… 1-6
Menu Screen (23) …………………………………………………………… 1-9
Hour Meter …………………………………………………………………….1-10
Fuel Gauge …………………………………………………………………….1-10
Clock ……………………………………………………………………………….1-10
Back Monitor Selector ………………………………………………….1-10
Menu Key ……………………………………………………………………….1-11
Optional Function Key …………………………………………………1-11
Return to Basic Screen Key …………………………………………1-11
Alarm Light ……………………………………………………………………1-11
Optional Function Display …………………………………………1-11
Coolant Temperature Gauge ………………………………………1-12
Operating Status Icon Display ……………………………………1-12
Alarm Occurrence Screen ………………………………………………….1-17
Contents of Alarms …………………………………………………………….1-19
Clock Setting ……………………………………………………………………….1-21
Attachment Selection
(Only Machines Equipped with Optional Parts) ………1-22
Pump 2 Flow Rate Adjustment
(Only Machines Equipped with Optional Parts) ………1-25
Displaying Operating Conditions …………………………………….1-26
Fuel Rate Display/No Display ……………………………………………1-27
Back Monitor Settings ……………………………………………………….1-35
Maintenance Settings ………………………………………………………..1-42
Mail (Optional) …………………………………………………………………….1-47
Language Settings ……………………………………………………………..1-49
Switch Panel ………………………………………………………………………..1-51
Engine Control Dial …………………………………………………………….1-52
Auto-idle Switch …………………………………………………………………1-52
Power Mode Switch …………………………………………………………..1-53
Travel Mode Switch ……………………………………………………………1-53
Work Light Switch ………………………………………………………………1-54
Wiper/Washer Switch …………………………………………………………1-55
Switch Panel (Optional Included) …………………………………….1-56
Fan Rotating Direction Device(Optional) ……………………….1-60
Key Switch ……………………………………………………………………………1-61
Power Boost Switch ……………………………………………………………1-61
Horn Switch …………………………………………………………………………1-61
Cigar Lighter ………………………………………………………………………..1-62
Cab Light ……………………………………………………………………………..1-63
Installing Fire Extinguisher (Optional) …………………………….1-63
Pilot Control Shut-off Lever ………………………………………………1-64
Engine Stop Switch …………………………………………………………….1-64
Fuse Box ……………………………………………………………………………….1-65
Additional Fuse Box ……………………………………………………………1-65
Air Conditioner Operation ………………………………………………..1-66
Auto Air Conditioner ………………………………………………………….1-67
Cab Heater Operation ………………………………………………………..1-72
Cooling Operation ……………………………………………………………..1-72
Defroster Operation …………………………………………………………..1-73
Tips for Optimal Air Conditioner Usage ………………………….1-74
AM/FM Radio Operation …………………………………………………..1-75
Digital Clock Setting Procedure ……………………………………….1-76
Cab Door Release Lever …………………………………………………….1-77
Opening Upper Front Window
(ZAXIS450-3, 450LC-3, 500LC-3) …………………………………..1-77
Closing Upper Front Window ……………………………………………1-78
Removing and Storing Lower Front Window
(ZAXIS450-3, 450LC-3, 500LC-3) …………………………………..1-79
Opening Side Windows ……………………………………………………..1-79
Opening/closing Overhead Window
(ZAXIS450-3, 450LC-3, 500LC-3) …………………………………..1-80
Opening/closing Overhead Window ………………………………1-80
Emergency Exit(ZAXIS450-3, 450LC-3, 500LC-3) ……………..1-81
Emergency Exit(ZAXIS470H-3, 470LCH-3, 520LCH-3) ……..1-82
Adjusting the Seat ……………………………………………………………..1-83
Adjusting the Seat (Heater Seat Optional) ……………………..1-85
Seat With a Built-in Heater ………………………………………………..1-86
Adjusting the Air-suspension Seat (Optional) ……………….1-87
Seat With a Built-in Heater ………………………………………………..1-88
Adjusting Console Height …………………………………………………1-89
Seat Belt ……………………………………………………………………………….1-90
BREAK-IN
Observe Engine Operation Closely …………………………………… 2-1
Every 8 Hours or Daily …………………………………………………………. 2-1
After the First 50 Hours ………………………………………………………. 2-1
After the First 100 Hours …………………………………………………….. 2-1
OPERATING the ENGINE
Inspect Machine Daily Before Starting …………………………….. 3-1
Before Starting Engine ……………………………………………………….. 3-2
Level Check …………………………………………………………………………… 3-3
Starting the Engine in Ordinary Temperature …………………. 3-4
Starting in Cold Weather ……………………………………………………. 3-5
Check Instruments After Starting ……………………………………… 3-6
Using Booster Batteries ………………………………………………………. 3-7
Stopping the Engine …………………………………………………………… 3-9
DRIVING the MACHINE
Drive the Machine Carefully ………………………………………………. 4-1
Steering the Machine Using Pedals ………………………………….. 4-2
Steering the Machine Using Levers ………………………………….. 4-3
Travel Mode Switch …………………………………………………………….. 4-4
Travel Alarm (Optional) ………………………………………………………. 4-4
Operating on Soft Ground …………………………………………………. 4-5
Raise One Track Using Boom and Arm …………………………….. 4-5
Towing Machine a Short Distance …………………………………….. 4-6
Operating in Water or Mud ………………………………………………… 4-7
Parking the Machine on Slopes …………………………………………. 4-8
Parking the Machine …………………………………………………………… 4-8
OPERATING the MACHINE
Control Lever (ISO Pattern) ………………………………………………… 5-1
Control Lever (HITACHI Pattern) ………………………………………… 5-2
Pilot Control Shut-off Lever ……………………………………………….. 5-3
Engine Speed Control …………………………………………………………. 5-6
Auto-idle ………………………………………………………………………………. 5-7
Work Mode …………………………………………………………………………… 5-8
Work Mode Select ……………………………………………………………….. 5-9
Power Boost ………………………………………………………………………..5-10
Power Mode ……………………………………………………………………….5-11
Operating Backhoe …………………………………………………………….5-12
Grading Operation ……………………………………………………………..5-12
Precaution for Arm Roll-in/ Bucket Roll-in Combined
Operation ……………………………………………………………………..5-13
Avoid Abusive Operation ………………………………………………….5-13
Operating Tips …………………………………………………………………….5-14
Select Correct Track Shoes ………………………………………………..5-14
Object Handling — If Equipped ……………………………………….5-15
Overnight Storage Instructions ………………………………………..5-17
ASSEMBLING
Precautions for Assembling ……………………………………………….. 6-1
Precautions for Slinging Work …………………………………………… 6-3
Precautions for Operating Machine …………………………………. 6-4
Installing Counterweight ……………………………………………………. 6-5
Installing Boom Cylinder ……………………………………………………. 6-6
Installing Boom ……………………………………………………………………. 6-8
Connecting Hoses Between Boom Cylinder and
Machine ………………………………………………………………………….. 6-9
Installing Boom Cylinder Rod …………………………………………..6-10
Installing Arm ……………………………………………………………………..6-11
Connecting Arm Cylinder Rod ………………………………………….6-12
Connecting Bucket Cylinder Hoses …………………………………6-13
Installing Bucket …………………………………………………………………6-14
Final Inspection …………………………………………………………………..6-15
Transporting by Road ………………………………………………………..6-16
Transporting the Machine by Trailer ……………………………….6-16
Loading/Unloading on a Trailer ……………………………………….6-16
ZAXIS450-3 (Backhoe) ………………………………………………………..6-20
CONTENTS
ZAXIS470H-3 (Backhoe) ……………………………………………………..6-24
ZAXIS450LC-3 (Backhoe) ……………………………………………………6-28
ZAXIS470LCH-3 (Backhoe) …………………………………………………6-32
ZAXIS500LCH-3 (Backhoe) …………………………………………………6-36
ZAXIS520LCH-3 (Backhoe) …………………………………………………6-40
Retracting or Extending the Side Frame …………………………6-44
Retracting the Side Frame …………………………………………………6-45
Extending the Side Frame …………………………………………………6-46
MAINTENANCE
Correct Maintenance and Inspection Procedures ………….. 7-1
Check the Hour Meter Regularly ……………………………………….. 7-2
Use Correct Fuels and Lubricants ……………………………………… 7-2
Prepare Machine for Maintenance ……………………………………. 7-3
Hood and Access Covers …………………………………………………….. 7-4
Periodic Replacement Of Parts ………………………………………….. 7-5
Maintenance Guide …………………………………………………………….. 7-6
A. Greasing …………………………………………………………………………… 7-9
Automatic Lubrication — If Equipped ………………………7-10
Front Joint Pins (Backhoe) …………………………………………..7-12
Swing Bearing ……………………………………………………………….7-14
Electric Grease Gun — If Equipped ……………………………7-15
Swing Internal Gear ……………………………………………………..7-19
B. Engine Oil ………………………………………………………………………..7-20
Engine Oil Level …………………………………………………………….7-21
Change Engine Oil ………………………………………………………7-22
Replace Engine Oil Filter ……………………………………………..7-22
C. Transmission Oil ……………………………………………………………..7-24
Swing Reduction Gear …………………………………………………7-25
Travel Reduction Gear ………………………………………………….7-26
D. Hydraulic System …………………………………………………………..7-28
Inspection and Maintenance of Hydraulic
Equipment ……………………………………………………………………..7-29
Check Hydraulic Oil Level ……………………………………………7-31
Drain Hydraulic Oil Tank Sump …………………………………..7-32
Change Hydraulic Oil …………………………………………………..7-33
Suction Filter Cleaning ……………………………………………….7-33
Replace Hydraulic Oil Tank Filter ………………………………..7-36
Replace Pump Drain Filter …………………………………………..7-37
Replace Pilot Oil Filter ………………………………………………….7-38
Replace Air Breather Element …………………………………….7-39
Check Hoses and Lines ………………………………………………..7-40
Service Recommendations for Hydraulic Fittings …………7-43
E. Fuel System …………………………………………………………………….7-45
Drain Fuel Tank Sump ………………………………………………….7-46
Check Water Separator ………………………………………………..7-47
Replace Fuel Main Filter Element ……………………………….7-50
Replace Fuel Pre-filter Element ………………………………….7-51
Clean Feed Pump Strainer ………………………………………….7-52
Check Fuel Hoses ………………………………………………………….7-53
F. Air Cleaner ………………………………………………………………………..7-54
Clean the Air Cleaner Outer Element ………………………..7-54
Replace the Air Cleaner Outer and Inner Elements …7-54
G. Cooling System ………………………………………………………………7-56
Check Coolant Level …………………………………………………….7-58
Change Coolant ……………………………………………………………7-59
Clean Radiator/ Oil Cooler/ Inter Cooler/
Fuel Cooler Core ……………………………………………………………7-60
Clean Oil Cooler Front Screen …………………………………….7-60
H. Air Conditioner ………………………………………………………………7-61
Clean and Replace Air Conditioner
Filter Clean Filter …………………………………………………………..7-62
Check Refrigerant (Gas) Quantity ………………………………7-64
Check Compressor Belt Tension …………………………………7-64
Clean Condenser Core …………………………………………………7-65
Check Looseness at Each of Fastened Areas …………….7-65
Check in-season and Off-season ………………………………..7-66
I. Electrical System ………………………………………………………………7-67
Batteries …………………………………………………………………………7-68
Replace Batteries ………………………………………………………….7-71
Replacing Fuses …………………………………………………………….7-72
Fuse Box …………………………………………………………………………7-72
Additional Fuse Box ……………………………………………………..7-72
J. Miscellaneous ………………………………………………………………….7-74
Check Bucket Teeth ………………………………………………………7-75
Change Bucket ……………………………………………………………..7-78
Adjust the Bucket Linkage (Backhoe) ……………………….7-79
Remove the Travel Levers ……………………………………………7-80
Check and Replace Seat Beltcheck ……………………………7-80
Check Windshield Washer Fluid Level ……………………….7-80
Check Track Sag ……………………………………………………………7-81
Clean Cab Floor — As Necessary ……………………………….7-83
Check Tightening Torque of Bolts and Nuts …………….7-84
Check O-rings in Bucket Joints …………………………………..7-97
Retighten Cylinder Head Bolt …………………………………….7-98
Inspect and Adjust Valve Clearance …………………………..7-98
Check Fuel Injection Timing ……………………………………….7-98
Measure Engine Compression Pressure ……………………7-98
Check Starter and Alternator ……………………………………..7-98
Check Water Pump ……………………………………………………….7-98
HYDRAULIC CIRCUIT AND ELECTRICAL CIRCUIT
Hydraulic System …………………………………………………………………. 8-1
Main Circuit ………………………………………………………………………….. 8-2
Electrical Circuit …………………………………………………………………… 8-4
Electrical Diagram ……………………………………………………………….. 8-5
MAINTENANCE UNDER SPECIAL
ENVIRONMENTAL CONDITIONS
Maintenance Under Special Environmental Conditions .. 9-1
STORAGE
Storing the Machine …………………………………………………………..10-1
Removing the Machine from Storage ……………………………..10-2
TROUBLESHOOTING
Engine …………………………………………………………………………………..11-1
Electrical System …………………………………………………………………11-5
Control Levers ……………………………………………………………………..11-9
Hydraulic System ………………………………………………………………..11-9
SPECIFICATIONS
Specifications (Backhoe)
ZAXIS450-3, ZAXIS450LC-3, ZAXIS500LC-3 ………………..12-1
Working Ranges (Backhoe)
ZAXIS450-3, ZAXIS450LC-3 …………………………………………..12-2
ZAXIS500LC-3 ………………………………………………………………..12-3
Shoe Types and Applications ……………………………………………12-4
ZAXIS450-3 …………………………………………………………………….12-4
ZAXIS450LC-3 ………………………………………………………………..12-4
ZAXIS500LC-3 ………………………………………………………………..12-5
Bucket Types and Applications (Backhoe) ……………………..12-6
ZAXIS450-3, ZAXIS450LC-3 …………………………………………..12-6
ZAXIS500LC-3 ………………………………………………………………..12-6
Specifications (Backhoe) ……………………………………………………12-7
ZAXIS470H-3, ZAXIS470LCH-3, ZAXIS520LCH-3 ………..12-7
Working Ranges (Backhoe) ……………………………………………….12-8
ZAXIS470H-3, ZAXIS470LCH-3, ZAXIS520LCH-3 ………..12-8
Shoe Types and Applications ……………………………………………12-9
ZAXIS470H-3 ………………………………………………………………….12-9
ZAXIS470LCH-3 ……………………………………………………………..12-9
ZAXIS520LCH-3 ………………………………………………………….. 12-10
Bucket Types and Applications (Backhoe) ………………….. 12-11
ZAXIS470H-3, ZAXIS470LCH-3, ZAXIS520LCH-3 …….. 12-11
Lifting Capacities …………………………………………………………….. 12-12
Sound Level Results (2000/14/EC) ……………………………….. 12-16
Vibration Level …………………………………………………………………. 12-16
OPTIONAL ATTACHMENTS and DEVICES
Hydraulic Breaker ……………………………………………………………….13-1
Work Mode ………………………………………………………………………….13-2
Breaker Operation ………………………………………………………………13-3
Precautions for Breaker Operation …………………………………..13-5
Breaker Maintenance …………………………………………………………13-9
Replace Breaker Circuit Return Oil Filter ……………………… 13-11
Hydraulic Crusher ……………………………………………………………. 13-12
Stop Valve Operation ……………………………………………………… 13-13
Three-way-valve Operation (Machines Equipped
with the Piping Common to Hydraulic Breaker
and Crusher Operation) …………………………………………… 13-14
Flow Combining Valve Operation ………………………………… 13-14
Precautions for Crusher Operation ………………………………. 13-15
INDEX …………………………………………………………………………………..14-1
